EP3114192B1 - Thermochemisches vefahren zur rückgewinnung von glasfaserverstärkter kunststoffabfallmaterie - Google Patents

Thermochemisches vefahren zur rückgewinnung von glasfaserverstärkter kunststoffabfallmaterie Download PDF

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EP3114192B1
EP3114192B1 EP15732041.7A EP15732041A EP3114192B1 EP 3114192 B1 EP3114192 B1 EP 3114192B1 EP 15732041 A EP15732041 A EP 15732041A EP 3114192 B1 EP3114192 B1 EP 3114192B1
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pyrolysis
chamber
fiberglass
pyrolysis chamber
temperature
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French (fr)
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EP3114192A2 (de
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Elio Santacesaria
Riccardo Tesser
Salvatore MALLARDO
Rosa VITIELLO
Martino Di Serio
Antonello DIMICCOLI
Laura SAVIANO
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Korec Srl
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Korec Srl
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Priority to SI201530580T priority Critical patent/SI3114192T1/sl
Priority to PL15732041T priority patent/PL3114192T3/pl
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Publication of EP3114192B1 publication Critical patent/EP3114192B1/de
Priority to HRP20190136TT priority patent/HRP20190136T1/hr
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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J11/00—Recovery or working-up of waste materials
    • C08J11/04—Recovery or working-up of waste materials of polymers
    • C08J11/10—Recovery or working-up of waste materials of polymers by chemically breaking down the molecular chains of polymers or breaking of crosslinks, e.g. devulcanisation
    • C08J11/12—Recovery or working-up of waste materials of polymers by chemically breaking down the molecular chains of polymers or breaking of crosslinks, e.g. devulcanisation by dry-heat treatment only
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10B—DESTRUCTIVE DISTILLATION OF CARBONACEOUS MATERIALS FOR PRODUCTION OF GAS, COKE, TAR, OR SIMILAR MATERIALS
    • C10B5/00—Coke ovens with horizontal chambers
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10B—DESTRUCTIVE DISTILLATION OF CARBONACEOUS MATERIALS FOR PRODUCTION OF GAS, COKE, TAR, OR SIMILAR MATERIALS
    • C10B53/00—Destructive distillation, specially adapted for particular solid raw materials or solid raw materials in special form
    • C10B53/07—Destructive distillation, specially adapted for particular solid raw materials or solid raw materials in special form of solid raw materials consisting of synthetic polymeric materials, e.g. tyres
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G1/00—Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal
    • C10G1/10—Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal from rubber or rubber waste
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2331/00—Characterised by the use of copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an acyloxy radical of a saturated carboxylic acid, or carbonic acid, or of a haloformic acid
    • C08J2331/02—Characterised by the use of omopolymers or copolymers of esters of monocarboxylic acids
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2367/00—Characterised by the use of polyesters obtained by reactions forming a carboxylic ester link in the main chain; Derivatives of such polymers
    • C08J2367/06—Unsaturated polyesters
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P20/00—Technologies relating to chemical industry
    • Y02P20/141—Feedstock
    • Y02P20/143—Feedstock the feedstock being recycled material, e.g. plastics

Definitions

  • the present invention relates to a process for the pyrolysis of fiberglass-reinforced plastic waste, in order to recover organic and inorganic components in such a state as to allow them to be advantageously reused as raw materials for making new objects.
  • waste are meant production scrapes and articles that are at the end of their life cycle, obsolete articles, or in any case articles that cannot be used any longer.
  • fiberglass-reinforced plastics means a structural composite material that includes a thermosetting resin matrix, normally 60-70% by weight, which is reinforced with glass fibers, and usually also contains pigments, additives and fillers.
  • the resin is obtained by crosslinking an orthophthalic, isophthalic or vinylester unsaturated polyester prepolymer, which is in turn obtained by a polycondensation reaction of saturated and unsaturated dicarboxylic acids with glycols, such as ethylene and/or propylene and/or neopentyl glycol.
  • the unsaturation degree can be determined as the iodine number.
  • an orthophthalic prepolymer normally has an iodine number I.N.
  • the prepolymer is dissolved into a solvent, e.g. styrene, about 40% by weight.
  • a solvent e.g. styrene
  • glass fibers can be used in the form of thin sheets or "mats" of a nonwoven fabric of glass threads including continuous or cut fibers, or in the form of tissues or mats having a desired pattern.
  • the industrial methods for making fiberglass-reinforced plastic structures which are still normally manual methods, comprise substantially contemporaneous steps of lamination, by which layers of resin and of glass fibers are alternately laid on one another, and steps of polymerization and reticulation, i.e. cross-bonding steps, by which the resin is hardened, in the presence of an organic peroxide catalyst.
  • Fig. 6 shows an example of a structure formula of a polyester resin obtained from fumaric acid.
  • a layer gelcoat is often used, i.e. a layer of a thixotropic coloured unsaturated polyester resin including pigments, additives and various fillers, which is laid on the mould immediately before the lamination step.
  • Fiberglass-reinforced composite materials including fiberglass-reinforced plastics, are commercially important since they provide particular combinations of different features that cannot be present at the same time in such traditional materials as metal alloys, ceramic materials and unreinforced polymer materials. These composites are very light, mechanically resistant, excellently durable, chemically resistant and have a low heat and electric conductivity.
  • fiberglass-reinforced plastics have been widely used since the 50's in many applications, initially as a material for aerospace applications and then also for making more common articles in the automotive industry (portions of car bodies, control panels, bumpers); in the nautical or marine industry (hulls, decks, masts, construction profiles, anchor buoys, protective structures for motors, internal panels); in the building sector (underground pipes, structural profiles, railings, roof gutters, doors or windows); in the chemical industry (pipes, tanks and pressure vessels, valves, pumps, impellers); in the electric industry (boards, electric boxes, switches, insulators, connectors, conduits); in the farm industry (storage bins, greenhouses, pileworks, fencings); in the sport industry (golf clubs, tennis rackets, sport helmets, skis, surf tables and snowboards, bows and arrows, bicycles, fishing rods, canoes, swimming pools).
  • the macromolecules of the material are broken, and an organic fraction comprising smaller molecules is normally produced as a liquid, or in any case as a condensable matter.
  • Cunliffe et al. [12] relate to a process for the pyrolysis of fiberglass-reinforced plastics under nitrogen that is carried out at 450°C and at atmospheric pressure, in which a gas is obtained containing CO, CO 2 , H 2 , CH 4 and other light hydrocarbons, as the result of the pyrolysis reactions; an oil is also obtained as well as a solid residue consisting of glass fibers and of a high amount of a pitch material, 16% by weight. The glass fibers are separated by burning the pitch material. By burning the organic gas, enough heat is obtained to cover the thermal requirements of the process.
  • a reference is made to the possibility of recycling such monomers as phthalic anhydride and styrene, of which the oil is rich, for producing a prepolymer and a polyester resin, respectively, provided the monomers are separated.
  • JP 2000 301131 A describes a process for treating discarded printed circuits (PCB, Printed Circuit Boards), in order to recover the metals therefrom, which is carried in the presence of nitrogen and of a certain amount of oxygen, up to 10% by volume, after which the circuits are heated up to a temperature of at least 250°C, and then cooling them down under an inert blanket, so as to cause an embrittlement of the plastic portion of the circuit and to assist milling and subsequent mesh separation of the metal, while the recovery of the polymer fraction is not described.
  • PCB discarded printed circuits
  • Printed Circuit Boards Printed Circuit Boards
  • Zhixiao Zhang relates to PCB including substrates containing an epoxy resin, and describes the use of microwaves to speed-up the nitrogen treatment.
  • This document also mentions the recovery of useful products such as phenol and bisphenol derivatives from the liquid matter obtained by treating the organic fraction, provided an expensive removal or destruction of possible bromine-containing compounds is carried out.
  • Xiaojuan Guo also deals with a pyrolysis treatment of printed circuits containing epoxy resins under nitrogen that produces a gas and low amounts of oil, which are burnt to provide the heat required to maintain the pyrolysis process.
  • thermochemical process for disposing a waste containing an unsaturated polyester resin, in particular a fiberglass-reinforced plastic waste, which makes it possible to recover an organic portion therefrom, which can be reused as such as a raw material, typically in mixture with an amount of fresh prepolymer, to produce a new radically crosslinkable resin, in particular a new polyester resin.
  • thermochemical process for disposing a fiberglass-reinforced plastic waste, which makes it possible to recover the inorganic portion of the waste, essentially glass fibers, in such amounts to allow a reuse in the same way as fresh glass fibers.
  • the recovered products of pyrolysis are advantageously subjected to analytical investigations, in particular, in order to establish their iodine number, which is an estimate of the number of double bonds that are present in the molecules and, therefore, allow assessing whether the latter can undergo crosslinking polymerization reactions.
  • a higher iodine number means a better suitability of the products of pyrolysis to be recycled into the production process of new fiberglass-reinforced plastic articles, in a mixture with the commercially available or fresh unsaturated polyester resins, which are free from recycled products.
  • the pyrolysis thermal treatment under a CO 2 flow allows very high yield values, both as absolute values and with respect to the yield values of other pyrolysis treatments.
  • the organic liquid yield surprisingly achieves values even higher than 80% by weight, therefore only a small amount of organic residue is produced which settles substantially only on the glass fibers, from which it can be easily separated.
  • Comparison tests have shown that conventional pyrolysis processes, which are carried out in a nitrogen or in a steam environment, definitely provide yield values lower than 48%, in spite of long residence times, and 56% by weight, respectively, and give rise to larger amounts of a carbonaceous and/or organic residue, for example of a pitch material, which in part settles on the glass fibers.
  • the steam pyrolysis produces a sticky organic liquid that forms colloids and more in particular emulsions with water, and that is difficult to separate from the emulsion water.
  • Example 2 provides an estimate of the yield values expected under optimal process conditions, according to the invention, which are surprisingly even higher than 96% by weight.
  • the organic liquid obtained by the process according to the invention is particularly suitable to be recycled to the production process of fiberglass-reinforced plastics, i.e. to a new polymerization as a mixture with commercial unsaturated resins.
  • the organic liquid obtained by a pyrolysis carried out in a CO 2 -containing environment has an iodine number as high as 77, instead of such values as 42 and 48 obtained in a nitrogen or steam pyrolysis, respectively.
  • Example 3 In which I.N. values are attained between 95 and 100. These values are comparable with the value of 179 of a corresponding fresh prepolymer, which contains, however, about 40% styrene, a highly unsaturated molecule. If styrene is distilled away, the iodine number of this prepolymer, alone, drops to 67. If styrene, and any possible volatile product, is removed from the pyrolysis organic liquid, the iodine number decreases to a value between 50 and 60, which is fully comparable with the iodine number of the fresh prepolymer without styrene. The high iodine numbers of the pyrolysis liquid without styrene and volatile compounds indicate that the pyrolysis liquid contains macromolecules providing double bonds available for a crosslinking reaction that would take place when recycling the pyrolysis organic liquid.
  • the fiberglass-reinforced plastic articles obtained from a raw material containing the organic product recovered by the pyrolysis of the invention show properties that are substantially unaffected with respect to fiberglass-reinforced plastics products obtained from commercial raw materials, but the cost of the are raw materials is remarkably lower.
  • unbroken and perfectly clean glass fibers can be easily obtained from the solid residue, which can therefore be recycled for making new articles, as discussed hereinafter.
  • a step can be provided of preliminarily reducing the size, or crushing, of the fiberglass-reinforced plastic waste, for example by a grinding step.
  • the step of removing oxygen can be carried out by causing a cold inert gas such as nitrogen or carbon dioxide itself to flow so as to purge the air completely from the pyrolysis chamber, and then pre-heating the pyrolysis chamber maintaining a flow of carbon dioxide, until said predetermined pyrolysis temperature is attained, and maintaining said predetermined pyrolysis pressure.
  • a cold inert gas such as nitrogen or carbon dioxide itself
  • the condensation step can be carried out in a condenser, which may comprise two or more serially connected containers cooled from the outside.
  • the step of creating a CO 2 -containing environment and the step of removing oxygen are carried out at the same time by a step of maintaining a substantially pure CO 2 flow through the pyrolysis chamber.
  • the heating step can be carried out at least in part by heating the stream of carbon dioxide once the limit value of oxygen concentration has been reached.
  • the pressure in the reactor can be adjusted at the predetermined level even since the beginning of the step of heating.
  • the step of creating a CO 2 -containing environment and the step of removing oxygen comprise alternating in the chamber at least one step of supplying an amount of an inert gas, in particular nitrogen, or an amount of substantially pure CO 2 , with at least one steps of creating a vacuum degree, and also comprises a final step of supplying a final amount of substantially pure CO 2 at a predetermined pressure after alternating the steps of supplying CO 2 and of creating a vacuum degree.
  • the residual oxygen concentration is lower than 10%, preferably is lower than 5%, in particular is lower than 2%, more in particular is lower than 1%.
  • the pyrolysis temperature is set between 400 and 500°C, preferably, between 400°C and 450°C.
  • the residence time of the waste in the pyrolysis chamber is preferably set between 1 and 2 hours, for example between 1.5 and 2 hours.
  • the step of maintaining the CO 2 -containing environment and the pyrolysis temperature in the chamber is carried out at a pressure set between 0.2 and 20 bar absolute, in particular at a pressure set between 1 and 10 bar absolute.
  • the step of maintaining the CO 2 -containing environment and the pyrolysis temperature in the chamber is carried out at a pressure higher than 6 bar absolute.
  • the step of maintaining the CO 2 -containing environment and the pyrolysis temperature in the chamber is carried out at a pressure higher than 73 bar absolute, i.e. at a supercritical pressure, i.e. at a pressure higher than the critical pressure of CO 2 . This further increases the yield and the viscosity of the liquid, as Example 4 still indicates.
  • the process can also comprise a step of collecting a non-condensable gas left by the step of condensing the gas mixture containing the products of pyrolysis, which contains CO 2 , and a step of recycling or recirculating this non-condensable gas into the pyrolysis chamber, which is carried out during the step of creating a CO 2 -containing environment and/or during the step of maintaining the CO 2 -containing environment and the pyrolysis temperature.
  • the non-condensable gas Before being recycled into the pyrolysis chamber, the non-condensable gas may undergo a purification step, in particular, in order to remove a vapor residue of the products of pyrolysis, for example by a combustion step, and/or in order to remove moisture from the non-condensable gas, for example by a condensation step.
  • a purification step in particular, in order to remove a vapor residue of the products of pyrolysis, for example by a combustion step, and/or in order to remove moisture from the non-condensable gas, for example by a condensation step.
  • a step can also be provided of washing the chamber, and/or the condenser, with a washing solvent, selected for instance among acetone; methyl-ethyl-ketone; tetrahydrofuran; styrene; methyl methacrylate, and mixtures thereof, so as to form a solution of further products of pyrolysis that were left back in the chamber solvent, as well as a step of removing this solution from the pyrolysis chamber.
  • a washing solvent selected for instance among acetone; methyl-ethyl-ketone; tetrahydrofuran; styrene; methyl methacrylate, and mixtures thereof.
  • steps can be provided of:
  • a step is provided of recovering the washing solvent, and a step of recirculating the washing solvent to a subsequent step of washing.
  • a step is provided of mixing the solution of the further products of pyrolysis with the products of pyrolysis recovered in the step of condensing the gas mixture, preferably according to proportions established in such a way to obtain a mixture that has a predetermined iodine number and/or a predetermined viscosity.
  • the methyl methacrylate or the styrene used as extraction solvent are not withdrawn from the organic liquid, but are left in the organic phase, since they also behave as reticulating monomers, during a subsequent production of new fiberglass-reinforced plastic objects. This further increases the iodine number of the recycled resin.
  • thermosetting polyester resin in particular an article made of a fiberglass-reinforced plastics
  • said thermosetting polyester resin is obtained starting from an unsaturated polyester resin comprising the above-mentioned products of pyrolysis.
  • the recovered resin can be mixed with the fresh prepolymer also at a very high percentage, since it has a full chemical compatibility with it.
  • some composite specimens are made by mixing commercially available virgin resins with the liquid produced by the pyrolysis according to the invention, according to weight proportions ranging from 5% to 20%. In no case drawbacks are observed during the polymerization.
  • the specimens had neither a lower mechanical resistance, nor a worse appearance, with respect to the specimens obtained starting from the virgin resin. Even larger amounts of recovered material can be used in the mixture with the fresh prepolymer, as the excellent quali-quantitative results of the tests of Example 5 suggest.
  • the solid residue left after the step of maintaining the CO 2 -containing environment and the pyrolysis temperature, i.e. after the pyrolysis, can also comprise a certain amount of a solid organic deposit, of which a separation step is provided from the glass fibers, i.e. a step is provided of purifying the latter, which is advantageously carried out as a step of heating and treating the solid residue in air at a temperature between 500°C and 750°C, preferably between 600°C and 700°C, for a predetermined time, so as to cause a combustion, i.e. to burn the solid organic deposit stuck on the glass fibers, in such a way that the solid residue contains substantially only an inorganic material comprising the glass fibers, at the end of this treatment.
  • the heating step and the treatment can be carried out in the pyrolysis chamber.
  • a step can be provided of conveying the solid organic deposit from the pyrolysis chamber into a combustion chamber where the step of heating up to the treatment temperature takes place, followed by the treatment, i.e. the calcination.
  • the process can also comprise a step of collecting a combustion gas produced in the step of heating and treating the solid residue, which contains CO 2 , as well a step can be provided of recycling or recirculating this combustion gas into the pyrolysis chamber, which is carried out during the step of creating a CO 2 -containing environment and/or during the step of maintaining the CO 2 -containing environment and the pyrolysis temperature.
  • the combustion gas Before being recycled into the pyrolysis chamber, the combustion gas may undergo a step of purification, in particular in order to remove moisture, for instance by condensation, and/or in order to remove impurities formed during the combustion, such as CO, NOx, hydrocarbons, for example by a catalytic oxidation.
  • the solid residue can also contain an inorganic particulate matter in the form of scales and dust, comprising in particular pigments, or fillers or additives of the fiberglass-reinforced plastic waste, in particular in the gelcoat portion that can be present in the waste.
  • a step is provided of recovering an amount of heat produced by said burn, and preferably also a step of exploiting the recovered heat for preheating the CO 2 gas and the fiberglass-reinforced plastic waste fed to the reactor.
  • the solid residue after combustion can be weighed in order to estimate the amount of the carbonaceous residue deposit that has been burnt, which has been done in the laboratory tests.
  • a step is provided of mechanically separating the glass fibers from the above-mentioned inorganic particulate matter.
  • Such mechanical separation step can comprise at least one step selected among the steps of separation by shaking, by blowing, by sifting the particulate, and other well-known methods for separating fractions of solids of different shape and size, in order to obtain a clean fiber matter.
  • Examples 1, 4 and 5 show, if the solid residue is treated as indicated above, unbroken and perfectly clean glass fibers are recovered, which are substantially in the same conditions as before the use. Therefore, the recovered fibers can completely replace new glass fibers blank in the production of new fiberglass-reinforced plastics semi-finished product and articles, or in any fiberglass-reinforced material.
  • these recovered fibers can be directly recycled as chopped strands, i.e. cut fibers, whose length usually ranges from 3 mm to 25 mm, or as milled fibers, i.e. ground fibers whose length is averagely between 0.1 mm and 0.5 mm, in particular between 0.1 mm and 0.2 mm, for the same applications as new glass fibers are used.
  • the cut fibers can be used for making the previously mentioned sheets or mats.
  • the cut fibers can also be reused in a resin matrix, by mixing them in a dry state, or by continuously feeding according to a prefixed weight or volume feed rate, or in the concrete and plaster matter.
  • the resin matrix can be used as a reinforcement charge in cast articles, in order to improve their resilience as well as in assembling mastics and plasters.
  • ground fibers can be used as a reinforcement material in:
  • Both types of fibers can be mixed with carbon and para-aramid fibers for making mixed tissues, in order to balance some features of these materials, to optimize some property/peso ratios and to reduce the production cost of the articles.
  • the reactor comprises a bed 51 of an inert filling material, for instance filling bodies such as Raschig rings, at a CO 2 inlet zone proximate to a CO 2 inlet port of the pyrolysis chamber, the filling material arranged to allow CO 2 to flow through said inert material bed 51 before reaching the waste material arranged in a filling material-free pyrolysis zone of the chamber, and arranged to transmit an amount of heat to the CO 2 so as to preheat the CO 2 before reaching the waste.
  • an inert filling material for instance filling bodies such as Raschig rings
  • the step of maintaining the CO 2 -containing environment and the pyrolysis temperature can comprise a step of continuously feeding substantially pure CO 2 into the pyrolysis chamber, whereas the step of extracting the gas mixture from the chamber is also carried out continuously during the step of maintaining the CO 2 -containing environment and the pyrolysis temperature, in order to keep a predetermined pressure within the chamber.
  • the step of feeding the waste into the pyrolysis chamber, and possibly also the step of extracting the solid residue is carried out continuously.
  • the continuous CO 2 feeding, the extraction of the gas mixture and the feeding of the waste into the pyrolysis chamber are carried out in such a way that a countercurrent flow is maintained of the gas stream that, when entering into the pyrolysis chamber, is substantially formed by the CO 2 as supplied and that, by flowing within the pyrolysis chamber, becomes richer in pyrolysis products forming said gas mixture containing pyrolysis products, on the one hand, and the solid stream that, by flowing within the chamber, turns from the waste into the solid residue, on the other hand.
  • Fig. 1 diagrammatically shows the process, according to an exemplary embodiment of the invention, for recovering the components of a waste 21 comprising an unsaturated polyester resin, for example an orthophthalic, an isophthalic or a vinylester resin, in particular a fiberglass-reinforced plastic waste.
  • an unsaturated polyester resin for example an orthophthalic, an isophthalic or a vinylester resin, in particular a fiberglass-reinforced plastic waste.
  • a step 110 is provided of feeding waste 21 into a pyrolysis chamber 52 of the reactor, a step 120 of removing atmospheric oxygen, until a predetermined residual concentration C R lower than 10% is reached, preferably lower than 5%, in particular lower than 2%, more in particular lower than 1%.
  • the predetermined residual concentration C R can also be a few ppm, and a step 125 is also provided of creating a CO 2 -containing environment, with a CO 2 volume concentration as high as or higher than 30%, preferably higher than 50%, more preferably higher than 80%.
  • a step 140 follows of maintaining the CO 2 -containing environment and pyrolysis temperature T P for a predetermined residence time, which depends on the pyrolysis temperature, during which a pyrolysis of the polyester resin occurs. With a pyrolysis temperature T P between 400°C and 450°C, the residence time can be chosen between 1 hour and 2 hours, in particular between 1.5 and 2 hours.
  • Pyrolysis 140 yields a gas mixture 30 containing pyrolysis products 33 and, in an exemplary embodiment of the process in which a fiberglass-reinforced plastic waste is treated, a solid residue 60 is also obtained comprising a glass fibers amount 62.
  • a step 150 follows of extracting gas mixture 30 from pyrolysis chamber 52 and a condensation 151 of pyrolysis products 33 from gas mixture 30, in a condensation chamber 10',10", as well as an extraction 160 of solid residue 60, if any.
  • Pyrolysis products 33 are preferably used in a production process, not shown, for making new articles comprising a thermosetting polyester resins, in particular fiberglass-reinforced plastic articles, where the polyester resin is obtained by crosslinking a mixture of a fresh unsaturated polyester resin and of pyrolysis products 33.
  • Steps 125 and 120 of creating the CO 2 -containing environment and of removing oxygen can be made at the same time ( Fig. 3 ) by causing a substantially pure CO 2 stream 20 to flow through pyrolysis chamber 52. Instead ( Fig. 2 ), these steps can be carried out by alternating at least one step 121 of supplying an amount of an inert gas, or of substantially pure CO 2 , with at least one step 122 of removing the gas so as to create a vacuum degree in pyrolysis chamber 52, and then by performing a final step 123 of supplying an amount 20' of substantially pure CO 2 at a prefixed pressure.
  • step 140 of pyrolysis i.e. while maintaining the CO 2 -containing environment and pyrolysis temperature T P , the CO 2 stream is fed substantially continuously to pyrolysis chamber 52, and extraction 150 of gas mixture 30 is carried out continuously as well, so as to maintain a predetermined pressure within pyrolysis chamber 52.
  • waste 21 feeding 110 can be carried out continuously as well.
  • the feeding of CO 2 , gas extraction 150 and waste 21 feeding 110 are carried out in such a way to maintain in pyrolysis chamber 52 countercurrent flow conditions of the gas stream that, when entering into the chamber, is substantially formed by supplied CO 2 20 and that, while flowing within pyrolysis chamber 52, becomes richer in pyrolysis products, forming gas mixture 30 containing the pyrolysis products, and of solid waste stream 21 being changed into solid residue 60.
  • these flow conditions can be created in a tubular pyrolysis reactor 5, such as a rotating oven.
  • solid residue 60 extraction 160 is carried out continuously.
  • Step 140 of maintaining the CO 2 -containing environment and pyrolysis temperature T P in pyrolysis chamber 52 can be carried out at a substantially atmospheric pressure, or at a pressure about 0.2 bar absolute, or at a pressure higher than the atmospheric pressure, which can be lower or higher than the critical pressure of CO 2 , which is about 73 bar absolute.
  • Fig. 5 Exemplary embodiments of the process are diagrammatically shown in Fig. 5 , where the main steps of Fig. 1 are represented by thick lines.
  • the steps shown in thin lines in the same figure are intended to be optional, and independent from one another, whereas the process alternatives are shown by dotted lines.
  • a step 152 can be provided of collecting a non-condensable gas 32, i.e. a gas residue of condensation 151, followed by a step 155 of recycling non-condensable gas 32 into pyrolysis chamber 52, during creation 125 of the CO 2 -containing environment and/or during pyrolysis 140.
  • non-condensable gas 32 may undergo a step 153 of removing a vapor residue 34 containing pyrolysis products, for example by a combustion, and/or a step 156 of removing a moisture amount 36, for example by a condensation.
  • combustion 153 for removing vapor residue 34 is carried out before moisture removal 156.
  • a step 170 is provided of washing pyrolysis chamber 52 and/or the condensation chamber with a solvent 40, after the extraction 150 of gas mixture 30 from pyrolysis chamber 52, so as to form a solution 42 of further pyrolysis products 44, which is withdrawn, 171, from pyrolysis chamber 52.
  • solvent 40 can be acetone, methyl-ethyl-ketone, tetrahydrofuran, alone or mixed with one another.
  • solvents advantageously undergo a separation 180 from further pyrolysis products 44, typically by evaporation or distillation, which can be followed by a step 185 of mixing the latter with pyrolysis products 33 obtained from condensation 151.
  • solvents can possibly be recovered and reused in a forthcoming washing step (not shown).
  • Solvent 40 can also be methyl-methacrylate or styrene, alone or mixed with each other, in this case the separation 180 is preferably omitted, and solution 42 advantageously undergo a step 186 of mixing with pyrolysis products 33 coming from condensation 151, preferably according to proportions established in such a way to obtain a predetermined iodine number and/or a predetermined viscosity of pyrolysis products after mixing step 186.
  • Solid residue 60 of pyrolysis 140 of fiberglass-reinforced plastic waste 21 typically comprises a solid organic deposit 64, which adheres on glass fibers 62.
  • the process provides a separation 190 of said deposit. Separation 190 is preferably carried out by treating solid residue 60 in air at a temperature set between 500°C and 750°C, preferably between 600°C and 700°C for a predetermined treatment time, so as to burn solid organic deposit 64 and to recover substantially clean glass fibers 62, apart from a possible inorganic dust and particulate due to additives that were present in the fiberglass-reinforced plastics or to a gelcoat layer, which can be removed, for instance, by simply shaking, or blowing or sifting the glass fibers.
  • a step can be provided, not shown, of recovering the heat produced by combustion 190, which can be used for preheating CO 2 20 and fiberglass-reinforced plastic waste 21 when fed to reactor 5.
  • Separation 190 can be carried out in pyrolysis chamber 52, or can be preceded by a step of conveying solid residue 60 from pyrolysis chamber 52 to a combustion chamber, not shown, where the residue can be heated up to the treatment temperature, followed by the treatment step, typically a calcination.
  • the process can comprise a step 192 of collecting a combustion gas 66 followed by recycling 195 combustion gas 66 into pyrolysis chamber 52, during creation 125 of the CO 2 -containing environment and/or during pyrolysis 140.
  • combustion gas 66 may undergo a removal 196 of a moisture amount 67, for example by condensation.
  • combustion gas 66 and/or non-condensable gas 32 may undergo (a) step/s 154 and/or 184 of purification to remove impurities possibly generated/left in combustion steps 153 and/or 190, which may contain, for instance, carbon monoxide, nitrogen oxides, or even hydrocarbons, the purification step 184 providing for instance a catalytic oxidation treatment.
  • combustion gas 66 and non-condensable gas 32 can be joined into one stream, not shown, which is recycled into pyrolysis chamber 52, during creation 125 of the CO 2 -containing environment and/or during pyrolysis 140.
  • this stream, before being recycled, may undergo a step 153 of removing a vapor residue containing pyrolysis products, for example by combustion, and/or a step 156 of removing a moisture amount, for example by condensation.
  • Recovered glass fibers 62 can be used in a production process, not shown, for making new articles of a fiberglass-reinforced composite material, in particular of fiberglass-reinforced plastics, fully or partially replacing fresh glass fibers.
  • Each tubular reactor comprised a portion of a length L r of 12.5 cm arranged between one end and a central pyrolysis chamber of length L p containing a bed 51 of an inert material consisting of Raschig rings, so that the reactor gas feed came into contact with inert material bed 51 before coming into contact with the waste in the pyrolysis chamber, so as to be preheated before reaching pyrolysis zone or chamber 52.
  • the laboratory reactor was arranged into an oven 6 provided with a temperature control system, so as to obtain a temperature between 400°C and 450°C in the pyrolysis chamber.
  • Another Raschig rings bed 51 was arranged at a reactor end portion of length L r of 12.5 cm, which was left out of oven 6.
  • waste 21 comprised plates of fiberglass-reinforced plastics based on unsaturated polyester resins, more in detail orthophthalic, isophthalic and vinylester resins, which had been broken into listels of suitable size, for example, 0.3 to 0.8 width x 1 to 6 cm length for a smaller laboratory reactor, and into listels of such sizes as 1 to 2 cm width and 10 to 15 cm length, for a larger laboratory reactor.
  • the pressure in the pyrolysis chamber was adjusted at a predetermined value since the beginning of the heating.
  • Fig. 4 is diagrammatical view of a possible production plant or line 100 for carrying out the process according to the invention. This diagrammatical view also relates to the laboratory equipment used to perform the pyrolysis tests in the presence of CO 2 , according to the invention, and in the presence of inert gas, according to reference well known methods, for the purpose of comparison.
  • Production line 100 comprises a preferably tubular reactor 5.
  • Line 100 and reactor 5 can be configured for continuously feeding both waste 21 and CO 2 20, and for continuously extracting the pyrolysis products, along with an excess CO 2 , so as to provide a continuous process.
  • reactor 5 can be a rotating oven.
  • line 100 and reactor 5 can be configured for arranging a charge of waste 21 in reactor 5 at the beginning of a pyrolysis cycle, for extracting a solid residue of the charge at the end of the cycle, for continuously feeding the CO 2 , and for continuously extracting the gas products of the pyrolysis along with the excess CO 2 , so as to provide a semicontinuous process.
  • line 100 and reactor 5 can be configured for arranging a charge of waste 21 and of CO 2 in reactor 5 at the beginning of a pyrolysis cycle and for extracting the solid residue and the gas pyrolysis products along with the excess CO 2 , so as to provide a batch process.
  • Production line 100 also comprises a carbon dioxide source 1, in the equipment used for the tests described hereinafter a gas bottle 1.
  • a control device is provided to adjust the carbon dioxide flowrate at a predetermined value, which comprises a flow sensor 2, which in the laboratory equipment was a flow meter associated with a hand control valve.
  • a remote control device 2' can be provided for remotely reading the and possibly record the CO 2 flowrate, which can also be associated to a control valve, not shown, operated by a control signal produced by remote control device 2' responsive to a flowrate set point and to a current flowrate value coming from sensor 2.
  • a device for measuring the temperature within reactor 5, which can comprise a plurality of sensors 4, such as thermocouples, arranged at respective positions within reactor 5.
  • a thermocouple 4 has been used slidably inserted within a sheath 4" consisting of a through stainless steel 1/8" (3,2 mm) tube, arranged along the axis of tubular reactor 5, whose reading position could be adjusted along the whole reactor length L, in order to determine the axial temperature profile.
  • reactor 5 was arranged in a tubular chamber of oven 6, with its two ends 5a, 5b protruding out of it, so as to easily reach the inlet and outlet ports of the gas and of the pyrolysis products, respectively.
  • the oven had a temperature control system 3 configured for establishing a predetermined temperature, in particular between 400°C and 450°C, within pyrolysis chamber 52 of reactor 5.
  • the reactors consisted of two tubes of the same length L of 85 cm, but of different inner diameters ⁇ , a smaller one, 15 mm, and a larger one, 40 mm, as diagrammatically shown in Fig. 8 . In both cases, the end portions of reactor 5 protruded by 12.5 cm out of the oven.
  • tubular pyrolysis reactor 5 comprises a preheating zone proximate to the inlet port of the waste.
  • This preheating zone preferably contains an inert material bed 51, for example comprising filling bodies such as Raschig rings, so that the gas fed to reactor 5 comes into contact with inert material bed 51 before coming into contact with the waste loaded in the reactor. This way, the gas can be preheated before reaching pyrolysis chamber 52, where waste 21 is arranged.
  • preheating zone 5a included Raschig rings at the end portion of reactor 5 that protruded out of oven 6.
  • Another Raschig rings bed 51 of 12.5 cm length was arranged at the opposite end portion to reactor 5, also protruding out of oven 6.
  • the pyrolysis products outlet port of reactor 5 is pneumatically connected with a collection vessel 7, preferably configured for containing a predetermined inner pressure.
  • Collection vessel 7 is advantageously provided with a refrigeration system 7', in particular, in the laboratory equipment, it is submerged by a cooling fluid, and with an inner pressure sensor.
  • a pressure control valve 9 is arranged along a vent duct 9' of collection vessel 7 in order to keep the pressure upstream of the valve 9 -and so within collection vessel 7- at a predetermined value, which is indicated by a pressure sensor 8.
  • a system 10 for condensing and collecting the pyrolysis products is also provided, which in the laboratory equipment is made consists of two serially arranged devices 10', 10", each comprising a collection vessel immersed in a cooling bath, and of a reflux condenser mounted to each vessel, working at atmospheric pressure.
  • a purge or vent duct 11 comes out of the second condenser for the uncondensed gas.
  • the smaller reactor has been used:
  • the samples have been taken from fiberglass-reinforced plastic waste coming from different industries, in the form of listels of predetermined standard size, which have been suitably mixed, in order to obtain samples that can represent the composition differences of the fiberglass-reinforced plastic waste that can occur in an industrial recovery process.
  • the resin/fiber ratio i.e. the organic/inorganic ratio can vary in a range of values, depending on the operator that carries out the production cycle, as well as on the performances of a particular article and on the related design specifications
  • different types of polyester resins can be used, i.e. orthophthalic, isophthalic or vinylester resins.
  • the samples to be tested were taken from the above-described mix of specimens.
  • fiberglass-reinforced plastic waste have been used made of unsaturated polyester resins of orthophthalic, isophthalic and vinylester type, obtained by a polycondensation reactions involving ethylene glycol, propylene glycol, and neopentyl glycol.
  • Example 1 Comparison of the efficiency of pyrolysis carried out in the presence of different gases, such as: nitrogen, steam, carbon dioxide, and check of the organic / inorganic ratio of the fiberglass-reinforced plastics
  • the recovered resin is 30.4% of the fiberglass-reinforced plastics initial weight. If only the organic compounds present in the fiberglass-reinforced plastics, in this tests 63.5% of the total weight, are taken as the reference for the yield, a value of 48% by weight can be calculated. From the mass balance, a loss of 3.17 g results that has not been collected along with the liquid obtained by condensation, which is 13.4% of the initial sample.
  • a visual examination of the fiberglass-reinforced plastics after the treatment has shown a copious carbonaceous deposit on the surface of the fibers. By calcinating the fibers covered with this deposit in air to 650°C for 5 hours, an amount of 8.65 g of clean glass fibers could be fully recovered, i.e. 36.5% of the initial fiberglass-reinforced plastics, which is an experimental value that fits the value obtained from the direct calcination test.
  • a portion of the pyrolysis liquid has been obtained by repeatedly washing the reactor and the connection tubes with acetone.
  • the fiberglass-reinforced plastics thermally treated by water, had a broken surface and shown a considerable carbonaceous deposit on the surface of the fibers, which completely disappeared, however, after 5 hours of calcination in air at 650°C.
  • the weight of carbonaceous deposit is 3.1 g, and the inorganic solid residue after calcination, experimentally evaluated, is 36.6% of the total weight, which fits with the 36.7% value obtained by direct calcination of a sample of the initial fiberglass-reinforced plastics.
  • the suspension of liquid residue and water at the outlet of the reactor has been subject to several separation and fresh water washing cycles. From the quantitative analysis of the unsaturations, an I.N.
  • the resin recovered both directly and by washing with acetone is 50.6% of the initial weight the fiberglass-reinforced plastics. If only the organic compounds present in the fiberglass-reinforced plastics, in this tests 63.5% of the total weight, are taken as the reference for the yield, a value of 80% by weight can be calculated, which is clearly higher than the yield obtained in the pyrolysis tests in nitrogen environment, 48%, and in a steam environment, 56%, even in the non-optimized operating conditions that can be obtained in a laboratory test. From the mass balance is a loss of 1.08 g results, which is 10.7% of the initial sample, due to material handling and/or to the formation of volatile compounds.
  • the pyrolysis under CO 2 allows an organic matter conversion as high as 97% by weight.
  • the thermal treatment under CO 2 yields a liquid residue that is more abundant and homogeneous than in the previous cases, and that is free from colloidal dispersions.
  • the viscous residue is less thick and sticky.
  • the sample, after the treatment, has a very thin, graphite-like carbonaceous, deposit, and after calcination at 650°C for 5h, the carbonaceous and/or organic deposit on the surface of the glass fibers is completely burnt, and 3.68 g of glass fibers are obtained, containing also the inorganic portion of the gelcoat, which can be easily separated by shaking or blowing the glass fibers, which is obtained therefore unbroken and perfectly clean.
  • experimental value of the solid residue after calcination is 36.5%, which fits the value of 36.7% obtained by direct calcination of the fiberglass-reinforced plastics.
  • Example 2 Thermogravimetric analysis of fiberglass-reinforced plastic samples under a CO 2 flow at various temperature, in order to identify the optimal process conditions.
  • thermogravimetric balance After realizing that the pyrolysis of the fiberglass-reinforced plastics in the presence of CO 2 makes it possible to recover substantially the whole organic portion as a polymerizable resin, thermal decomposition tests have been carried out on small fiberglass-reinforced plastic samples in a thermogravimetric balance, under a CO 2 flow and at three different pyrolysis temperatures, i.e. at 350°C, 375°C and 425°C, in order to evaluate:
  • the time for a complete pyrolysis is about one hour at 420°C and about 2 hours at 375°C, while 4 to 5 hours are required at 350°C.
  • the pyrolysis is particularly quick, since a weight loss is observed of about 62% in only 75 minutes, and some effects are already apparent at about 375°C. Therefore, it is preferable to maintain the pyrolysis temperature between 400°C and 450°C during 1.5 - 2 hours.
  • a series of preliminary pyrolysis tests has been carried out on larger amounts of fiberglass-reinforced plastics to prepare amount of pyrolysis products large enough to evaluate their recyclability in technological tests to be performed on specimens made by a manufacturer of fiberglass-reinforced plastic articles, as described in Example 5. All the tests have been made in the same conditions in order to evaluate the reproducibility of the properties of the fiberglass-reinforced plastics, by using the larger tubular reactor 5 ( Fig. 8 ), which has an inner diameter ⁇ of 40 mm ( Figs. 8 and 9 ), according to a scheme as shown in Fig. 4 . For each test, about 350 grams of fiberglass-reinforced plastics, in the form of listels ( Figs.
  • Waste 21 have been packed in the reactor 2 by arranging most of them in the zone heated by the oven.
  • the profile heat in the reactor ( Fig. 7 ) has been determined by causing a thermocouple to slide within a through stainless steel 1/8" (3,2 mm) tube, arranged along the whole axis of the reactor, and by reading the temperature in several points.
  • the pressure in reactor 5 and in the first collection vessel 7' has been maintained at the predetermined value by means of pressure control valve 9 arranged on vent line 9' of vessel 7 ( Fig. 4 ).
  • the first six tests have been made using a residence time of 2.5 hours in the reactor, of which 1.5 hours heating and 1 hour maintaining the pyrolysis temperature.
  • a temperature of 410-420°C was ensured in about 60% of length L of the reactor, whereas two opposite end portions, of 10 cm and 20 cm length, were at a lower temperature, between 330 and 410°C, and between 370 and 420°C, respectively at the inlet of the CO 2 and the outlet of the gas.
  • the first six tests have confirmed the optimal reaction time evaluated by the thermogravimetric analysis of Example 2, and have confirmed the reproducibility of the results in terms of yield and of Iodine Number with respect to the values obtained in Example 1 using the smaller reactor.
  • reaction time has been prolonged to 2 hours, at a temperature about 30°C higher than the profile of Fig. 7 , on average, i.e. reaching a value of about 450°C in the central part of the reactor.
  • the liquid resulting from washing the reactor has then been joined to the liquid of the flask, and acetone has been evaporated in order to recover an organic liquid containing the pyrolysis products of the fiberglass-reinforced plastics, which has subsequently been put into a stove to remove any acetone traces. Then, the liquid has been weighed in order to determine the process yield in organic liquid, i.e. in pyrolysis products.
  • the iodine number I.N. of the pyrolysis liquid has then been measured, which was always set between 95 and 100.
  • a fresh prepolymer normally used for making fiberglass-reinforced plastic articles has an I.N. of 179.8, which drops to 67 if the styrene, which is present in the mixture as a solvent, is evaporated. Since the liquid containing the pyrolysis products according to the process contains lower styrene amounts, the iodine number of the recovered resin is fully comparable with the one of the fresh prepolymer.
  • the losses after pyrolysis can depend on both organic non-condensable compounds and on the resin lost due to various manipulations or stuck on the surfaces of the laboratory equipment.
  • the yield estimate instead, has been made under the assumption, as in Example 1, that a weight amount of 63.3% of the initial mass of the organic material is present in the treated fiberglass-reinforced plastics. In the tests 1-6, the yield was between 58% and 63%.
  • the solid residue left in the reactor at the end of the step of maintaining the temperature, i.e. at the end of the pyrolysis, can be weighed for checking the weight loss and for comparing it with the weight of the collected liquid sample.
  • the discharged solid, comprising glass fibers and resin residues is black due to the deposits of carbonaceous and/or organic matter.
  • Figs. 19 and 20 show samples of glass fibers at the end of the pyrolysis and after the calcination, respectively. In Fig. 19 , a low organic material amount can be observed which forms a deposit on the glass fibers, and blackens them. Fig. 20 shows that the glass fibers are perfectly clean, after separating the organic waste from the inorganic fraction, in particular by calcination.
  • Pyrolysis tests have been carried out in a CO 2 -containing environment at pressures higher than the atmospheric pressure, in order to test the effect on the yield of the pyrolysis and on the processability of the pyrolysis organic products, as well as on the possibility to recycle them to a production process for making new fiberglass-reinforced plastic articles.
  • a first test (No. 8) has been made with the same apparatus of Fig. 4 , using the larger tubular reactor ( Fig. 8 ) by suitably adjusting the flow, according to the prefixed temperature and pressure, in order to allow the condensation, in one or more containers downstream of the pyrolysis reactor, substantially of the whole organic material removed by the CO 2 , in particular at about 8 bar and a flowrate of 20 cm 3 /minute, for a duration of 2.5 hours, of which 1.5 hours for reaching the pyrolysis temperature, 420°C, and 1 hour maintaining this temperature.
  • the results of the test are given in table 4.
  • the yield has been estimated as in Example 3, i.e. by assuming an organic content of the initial sample of 63.3% by weight.
  • the above comments about the yield and of the temperature profile of the test of table 3 applies also to this case.
  • a second test (n.9) has been performed at the same pyrolysis temperature, but at supercritical pressures and in static conditions, within the smaller tubular reactor, which was closed to one end.
  • the reactor After introducing the fiberglass-reinforced plastic waste, the reactor has been filled with CO 2 to an initial pressure of 15 bar absolute, heated up to a temperature of 420°C and then brought to a pressure of about 75 bar, still by introducing always with CO 2 .
  • the sample was not kept under a gas flow at atmospheric pressure or at about 8 bar, instead, it was brought under a static CO 2 pressure of about 75 bar and maintained in these conditions for 5 hours.
  • the amount of recovered resin, only liquid, is 53.7% of the initial weight the fiberglass-reinforced plastics. If only the organic compounds present in the fiberglass-reinforced plastics, in this tests 63.6% of the total weight, are taken as the reference for the yield, a value of 84.4% by weight can be calculated. From the mass balance, a loss of 0.42 g results that has not been collected along with the liquid obtained by condensation, which is 4.0% of the initial sample weight, whereas the carbonaceous and/or organic deposit on the glass fibers, in the form of a pitch material, is about the 5.9% by weight. The amount of solid residue after calcination, comprising the glass fibers and the inorganic portion of the gelcoat, fits with the values obtained in the other tests. The yield, considering the conditions of this test, i.e. the batch mode, is promising in view of the industrial application.
  • Example 5 Industrial technological recycle tests to assess polymerizability of the recovered organic liquid and the mechanical resistance of the fiberglass-reinforced plastic articles made by using various amounts of the recycled product.
  • the specimens have been manufactured by the contact shaping technology, also known as manual stratification or hand lay-up technique, which provides three main steps as described hereinafter:
  • Virgin gelcoat and lamination resin have been used based on orthophthalic resins, even if other types of polyester resins can be used, for example isophthalic resins and vinylester resins.
  • a reference specimen has also been made exclusively from a virgin polyester resin obtained from the same production lot, without adding any pyrolysis products.
  • a same waxed and gel coated mould has been used to manufacture all the specimens, in order to prevent differences due to a different execution of the waxing and of the gel-coating steps.
  • the gelcoat and the resin, containing cobalt octanoate as a chain initiator, have been applied after adding 2% Methyl-ethyl ketone peroxide as a catalyst.
  • the mechanical behavior is in any case remarkably affected by the cooperation between the reinforcing material and the matrix, i.e. by the interface adhesion between the matrix and the fibers.
  • the tensile and bending strength values Rt it is understood that this cooperation is not at all deteriorated by the recycled product present in the polymer matrix. Therefore, the final product according to the present invention is actually and fully recyclable and allows industrial applications in the manufacture of industrial articles whose performances are fully equivalent to the ones provided by the conventional fiberglass-reinforced plastic articles, in normal use conditions.

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Claims (15)

  1. Verfahren zur Behandlung eines glasfaserverstärkten Kunststoffabfalls, umfassend:
    - eine Matrix aus einem ungesättigten Polyesterharz;
    - in die Matrix eingearbeitete Verstärkungsglasfasern,
    wobei das Verfahren die folgenden Schritte umfasst:
    - Voranordnen (105) eines Reaktors (5) umfassend eine Pyrolysekammer;
    - Zuführen (110) des glasfaserverstärkten Kunststoffabfalls (21) in die Pyrolysekammer (52);
    - Entfernen (120) von Sauerstoff aus der Pyrolysekammer (52) bis zu einer vorbestimmten Restsauerstoffkonzentration (CR);
    - Erzeugen (125) einer CO2-haltigen Umgebung in der Pyrolysekammer (52) mit einer CO2-Volumenkonzentration von mindestens 30 %;
    - Erhitzen (130) des glasfaserverstärkten Kunststoffabfalls (21) in der Pyrolysekammer (52) und Erreichen (131) einer zwischen 350 °C und 550 °C eingestellten Pyrolysetemperatur (TP);
    wobei der Schritt eines Entfernens (120) von Sauerstoff und der Schritt eines Erreichens (131) einer Pyrolysetemperatur (TP) auf eine Weise durchgeführt werden, dass die Restsauerstoffkonzentration (CR) vor Erreichen der Pyrolysetemperatur (TP) erreicht wird;
    - Aufrechterhalten (140) der CO2-haltigen Umgebung und der Pyrolysetemperatur (TP) in der Pyrolysekammer (52) über eine vorgegebene Verweilzeit, womit Folgendes erhalten wird
    - ein Gasgemisch (30), das Pyrolyseprodukte des ungesättigten Polyesterharzes enthält, und
    - ein fester Rest (60), der die Glasfasern (62) umfasst;
    - Extrahieren (150) des Gasgemischs (30) aus der Pyrolysekammer (52);
    - Kondensieren (151) der Pyrolyseprodukte aus dem Gasgemisch (30) in einer Kondensationskammer, um eine flüssige Kondensatphase (33) zu erhalten, die eine Hauptmenge des Pyrolyseprodukts umfasst, die von dem nicht kondensierten Gas getrennt wird, sodass die organische Flüssigkeit (33) als solche zu einem Produktionsprozess von glasfaserverstärkten Kunststoffen als ein Gemisch mit kommerziell ungesättigten Polyesterharzen rückgeführt werden kann;
    - Extrahieren (160) des festen Rests (60) aus der Pyrolysekammer (52).
  2. Verfahren nach Anspruch 1, wobei die Restsauerstoffkonzentration (CR) niedriger als 10 % ist, insbesondere niedriger als 5 %, spezifischer niedriger als 2 %, noch spezifischer niedriger als 1 %.
  3. Verfahren nach Anspruch 1, wobei die Pyrolysetemperatur (TP) zwischen 400 und 500 °C eingestellt ist, insbesondere ist die Pyrolysetemperatur (TP) zwischen 400 °C und 450 °C eingestellt.
  4. Verfahren nach Anspruch 3, wobei die Verweilzeit zwischen 1 und 2 Stunden eingestellt ist, insbesondere zwischen 1,5 und 2 Stunden.
  5. Verfahren nach Anspruch 1, wobei der Schritt (140) eines Aufrechterhaltens der CO2-haltigen Umgebung und der Pyrolysetemperatur (Tp) in der Pyrolysekammer (52) bei einem Druck durchgeführt wird, der aus der Gruppe ausgewählt ist, die aus Folgendem besteht:
    - einem eingestellten Absolutdruck zwischen 0,2 und 20 bar, insbesondere bei einem eingestellten Absolutdruck zwischen 1 und 10 bar;
    - bei einem Absolutdruck über 73 bar, d. h. bei einem Absolutdruck, der höher als der kritische Druck von CO2 ist.
  6. Verfahren nach Anspruch 1, umfassend:
    - einen Schritt eines Sammelns (152) eines nicht kondensierbaren Gases (32), das durch den Schritt (151) eines Kondensierens des Pyrolyseprodukte enthaltenden Gasgemischs (30) zurückbleibt, wobei das nicht kondensierbare Gas CO2 enthält, und
    - einen Schritt einer Rückführung (155) des nicht kondensierbaren Gases (32) in die Pyrolysekammer (52), der während des Schritts (125) eines Erzeugens einer CO2-haltigen Umgebung und/oder während des Schritts (140) eines Aufrechterhaltens der CO2-haltigen Umgebung und der Pyrolysetemperatur durchgeführt wird.
  7. Verfahren nach Anspruch 6, umfassend einen Schritt eines Entfernens (153) einer Substanz, die aus der Gruppe ausgewählt ist, die aus Folgendem besteht:
    - einem Dampfrückstand (34) der Pyrolyseprodukte (33);
    - Feuchtigkeit (36)
    aus dem nicht kondensierbaren Gas (32), wobei der Schritt eines Entfernens (153) vor dem Schritt des Rückführens (155) des nicht kondensierbaren Gases (32) durchgeführt wird,
    insbesondere der Schritt eines Entfernens eines Dampfrückstands (34) der Pyrolyseprodukte (33) einen Verbrennungsschritt (153) umfasst, dem das nicht kondensierbare Gas (32) zugeführt wird,
    insbesondere der Schritt eines Entfernens von Feuchtigkeit einen Kondensationsschritt (156) umfasst, dem das nicht kondensierbare Gas (32) zugeführt wird.
  8. Verfahren nach Anspruch 1, umfassend einen Schritt eines Waschens (170) der Pyrolysekammer (52) und/oder der Kondensationskammer mit einem Lösungsmittel (40), der nach dem Schritt eines Extrahierens (150) des Gasgemischs (30) aus der Pyrolysekammer (52) durchgeführt wird, um eine Lösung (42) weiterer Pyrolyseprodukte (44) in dem Lösungsmittel (40) zu bilden, und einen Schritt eines Entfernens (171) der Lösung (42) aus der Pyrolysekammer (52),
    wobei das Lösungsmittel (40) aus Folgenden ausgewählt ist:
    - aus der Gruppe bestehend aus: Aceton; Methylethylketon; Tetrahydrofuran; Gemischen davon;
    - aus der Gruppe bestehend aus Methylmethacrylat und Styrol,
    insbesondere umfasst das Verfahren einen Schritt eines Mischens (186) der Lösung (42) der weiteren Pyrolyseprodukte (44), die Methylmethacrylat und/oder Styrol enthalten, mit den Pyrolyseprodukten (33), die in dem Schritt des Kondensierens (151) aus dem Gasgemisch (30) gewonnen werden,
    insbesondere wird der Schritt eines Mischens (186) durchgeführt, um ein Gemisch (33) mit einer vorbestimmten Jodzahl und/oder Viskosität zu erhalten.
  9. Verfahren nach Anspruch 1, wobei der feste Rest (60) auch eine Menge einer festen organischen Ablagerung (64) umfasst und das Verfahren einen Schritt eines Abtrennens (190) der festen organischen Ablagerung (64) von den Glasfasern (62) umfasst,
    wobei der Schritt eines Abtrennens der festen organischen Ablagerung (64) von den Glasfasern (62) einen Schritt (190) eines Erhitzens und Behandelns des festen Rests (60) in Luft bei einer Behandlungstemperatur umfasst, die für eine vorbestimmte Zeit zwischen 500°C und 750 °C eingestellt ist, um eine Verbrennung der festen organischen Ablagerung (64) zu bewirken und die Glasfasern (62) von der festen organischen Ablagerung (64) zu befreien,
    wobei das Verfahren insbesondere umfasst:
    - einen Schritt eines Sammelns (192) eines Verbrennungsgases (66), das in dem Schritt (190) eines Erhitzens und Behandelns des festen Rests (60) erzeugt wird, und
    - einen Schritt eines Rückführens (195) des Verbrennungsgases (66) in die Pyrolysekammer (52), der während des Schrittes (125) eines Erzeugens einer CO2-haltigen Umgebung und/oder während des Schrittes (140) eines Aufrechterhaltens der CO2-haltigen Umgebung und der Pyrolysetemperatur durchgeführt wird.
  10. Verfahren nach Anspruch 1, wobei der Schritt (105) eines Voranordnens eines Pyrolysereaktors (5) einen Schritt eines Anordnens eines Betts (51) aus einem inerten Füllmaterial (5") in die Pyrolysekammer (52) an einer Einlasszone des CO2 in der Nähe einer Einlassöffnung des CO2, durch die das CO2 in die Pyrolysekammer (52) zugeführt wird, umfasst, wobei das Füllmaterial (5") so angeordnet ist, dass das CO2 von der Einlassöffnung zu einer Zone in der Pyrolysekammer (52) fließen kann, die frei von dem Füllmaterial ist, und angeordnet ist, um eine Wärmemenge an das CO2 zu übertragen, um das CO2 vorzuwärmen.
  11. Verfahren nach Anspruch 1, wobei
    - der Schritt (140) eines Aufrechterhaltens der CO2-haltigen Umgebung und der Pyrolysetemperatur (TP) einen Schritt einer kontinuierlichen Zufuhr von im Wesentlichen reinem CO2 in die Pyrolysekammer (52) umfasst, und
    - der Schritt eines Extrahierens (150) des Gasgemischs (30) aus der Pyrolysekammer (52) kontinuierlich während des Schritts (140) eines Aufrechterhaltens der CO2-haltigen Umgebung und der Pyrolysetemperatur durchgeführt wird, um einen vorbestimmten Druck in der Pyrolysekammer (52) zu halten.
  12. Verfahren nach Anspruch 1, wobei der Schritt eines Zuführens (110) des glasfaserverstärkten Kunststoffabfalls (21) in die Pyrolysekammer (52) kontinuierlich während des Schritts (140) eines Aufrechterhaltens der CO2-haltigen Umgebung und der Pyrolysetemperatur durchgeführt wird.
  13. Verfahren nach Anspruch 12, wobei der Schritt eines Extrahierens (160) des festen Rests (60) aus der Pyrolysekammer (52) kontinuierlich während des Schritts (140) eines Aufrechterhaltens der CO2-haltigen Umgebung und der Pyrolysetemperatur durchgeführt wird.
  14. Verfahren nach den Ansprüchen 12 und 13, wobei die Schritte eines kontinuierlichen Zuführens von CO2, der Schritt eines Extrahierens (150) und der Schritt eines Zuführens (110) des glasfaserverstärkten Kunststoffabfalls (21) so ausgeführt werden, dass ein Gegenstromfluss innerhalb der Pyrolysekammer (52) von Folgendem aufrechterhalten wird:
    - einerseits einem Strom, der beim Eintritt in die Pyrolysekammer (52) im Wesentlichen durch das CO2 wie zugeführt gebildet wird, und der durch Fließen in der Pyrolysekammer (52) reicher an Pyrolyseprodukten wird, die das Pyrolyseprodukte enthaltende Gasgemisch (30) bilden, und
    - andererseits einem festen Strom, der von dem glasfaserverstärkten Kunststoffabfall (21) in den festen Rest (60) übergeht.
  15. Verfahren zum Behandeln eines ungesättigten Polyesterharzabfalls, umfassend die folgenden Schritte:
    - Voranordnen (105) eines Reaktors (5) umfassend eine Pyrolysekammer;
    - Zuführen (110) des ungesättigten Polyesterharzabfalls (21) in die Pyrolysekammer (52);
    - Entfernen (120) von Sauerstoff aus der Pyrolysekammer (52) bis zu einer vorbestimmten Restsauerstoffkonzentration (CR);
    - Erzeugen (125) einer CO2-haltigen Umgebung in der Pyrolysekammer (52) mit einer CO2-Volumenkonzentration von mindestens 30 %;
    - Erhitzen (130) des ungesättigten Polyesterharzabfalls (21) in der Pyrolysekammer (52) und Erreichen (131) einer zwischen 350 °C und 550 °C eingestellten Pyrolysetemperatur (Tp);
    wobei der Schritt eines Entfernens (120) von Sauerstoff und der Schritt eines Erreichens (131) einer Pyrolysetemperatur (TP) auf eine Weise durchgeführt werden, dass die Restsauerstoffkonzentration (CR) vor Erreichen der Pyrolysetemperatur (TP) erreicht wird;
    - Aufrechterhalten (140) der CO2-haltigen Umgebung und der Pyrolysetemperatur (TP) in der Pyrolysekammer (52) über eine vorgegebene Verweilzeit, um ein Gasgemisch (30) zu erhalten, das Pyrolyseprodukte des ungesättigten Polyesterharzes enthält;
    - Extrahieren (150) des Gasgemischs (30) aus der Pyrolysekammer (52);
    - Kondensieren (151) der Pyrolyseprodukte aus dem Gasgemisch (30) in einer Kondensationskammer, um eine flüssige Kondensatphase (33) zu erhalten, die eine Hauptmenge des Pyrolyseprodukts umfasst, die von dem nicht kondensierten Gas getrennt wird, sodass die organische Flüssigkeit (33) als solche zu einem Produktionsprozess von glasfaserverstärkten Kunststoffen als ein Gemisch mit kommerziell ungesättigten Harzen rückgeführt werden kann.
EP15732041.7A 2014-03-04 2015-03-04 Thermochemisches vefahren zur rückgewinnung von glasfaserverstärkter kunststoffabfallmaterie Active EP3114192B1 (de)

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PL15732041T PL3114192T3 (pl) 2014-03-04 2015-03-04 Sposób termochemiczny odzyskiwania odpadów tworzyw sztucznych wzmocnionych włóknem szklanym
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DE102019212441A1 (de) * 2019-08-20 2021-02-25 BKRZ GmbH Verfahren zum Recyceln von Dämmwolle, Vorrichtung zum Aufarbeiten von Dämmwolle, Faserverstärkter Schaum, Brennwiderstandsfähiger Holzwerkstoff sowie Verfahren zum Herstellen eines brennwiderstandsfähigen Holzwerkstoffs
CN110578542B (zh) * 2019-09-19 2020-09-08 中国矿业大学 一种高应力冲击地压巷道锚杆、设计方法和工作方法
CN110530114B (zh) * 2019-09-25 2024-01-02 深圳星河环境股份有限公司 一种基于微波热脱水的pcb膜渣减量化处理系统和方法
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TR201901092T4 (tr) 2019-02-21
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PL3114192T3 (pl) 2019-06-28
HUE042504T2 (hu) 2019-07-29
US20170218164A1 (en) 2017-08-03
CN106103562B (zh) 2019-06-18
SI3114192T1 (sl) 2019-03-29
DK3114192T3 (en) 2019-02-18
US10308784B2 (en) 2019-06-04
BR112016019645B1 (pt) 2021-03-09

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